Buckle assembly with disengagement prevention device

ABSTRACT

A buckle assembly with a disengagement prevention device and a method for using the same is disclosed. The buckle assembly has a first buckle member having a first strap holding structure configured to adjustably affix the first buckle member to a first strap segment. A second buckle member is configured to couple with the first buckle member, the second buckle member having a second strap holding structure configured to affix the second buckle member to a second strap segment. A disengagement prevention device is configured for engagement with the first and second buckle members to maintain the first and second buckle members in a coupled state under conditions where the first and second buckle members are not properly engaged or the engagement between the first and second buckle members is accidentally released.

BACKGROUND Field

The present disclosure relates generally to buckles, and morespecifically, the present disclosure relates to a buckle assemblyequipped with a disengagement prevention device.

Background Information

Buckles, such as side release buckles, are used in varied applicationsranging from closures on backpacks to safety harnesses used in infantcar seats, and rock-climbing harnesses. Side release buckles, whenproperly engaged, form a strong interconnect. However, side releasebuckles can become accidentally decoupled as, for example, when the malebuckle member is not properly engaged with the female buckle member.Since side release buckles are often used to secure harnesses and othersafety devices, a failure of such side release buckles can havecatastrophic results. Thus, a need exists for a buckle assembly, such asof the side release buckle type, having a disengagement preventiondevice.

SUMMARY

In one aspect, the present disclosure provides a buckle assembly. In oneembodiment, the buckle assembly includes a first buckle member having afirst strap holding structure configured to adjustably affix the firstbuckle member to a first strap segment, and a second buckle memberconfigured to couple with the first buckle member, the second bucklemember having a second strap holding structure configured to affix thesecond buckle member to a second strap segment. A disengagementprevention device is configured for engagement with the first and secondbuckle members to maintain the first and second buckle members in acoupled state under conditions where the first and second buckle membersare not properly engaged or the engagement between the first and secondbuckle members is accidentally released.

According to an embodiment of the present disclosure, the disengagementprevention device comprises a securing loop having a first side attachedto the second buckle member and a second side configured to engage withthe first buckle member. According to a feature of this embodiment, whenthe first buckle member becomes at least partially disengaged from thesecond buckle member, the second side of the securing loop becomesclamped between the first strap segment and the first buckle member.

In another embodiment, the buckle assembly includes a male bucklemember, a female buckle member, and a disengagement prevention deviceconfigured for engagement with the male and female buckle members tomaintain the male and female buckle members in a coupled state underconditions where the male and female buckle members are not properlyengaged or the engagement between the male and female buckle members isaccidentally released. The male buckle member includes an insertionportion having a pair of opposing locking structures disposed at adistal end of the insertion portion, and a first strap holding structureformed at a proximal end of the insertion portion, the first strapholding structure being configured to affix the male buckle member to afirst strap segment. The female buckle member includes a receiving voidand a second strap holding structure. The receiving void is configuredto receive the insertion portion of the male buckle member and hasopenings extending perpendicular to a long axis of the female bucklemember, the openings being configured to holdingly receive therespective locking structures. The second strap holding structure isformed opposite to the receiving void, the second strap holdingstructure being configured to affix the female buckle member to a secondstrap segment.

According to an embodiment of the present disclosure, the disengagementprevention device comprises a securing loop having a first side attachedto the female buckle member and a second side configured to engage withthe male buckle member. According to a feature of this embodiment, whenthe male buckle member becomes at least partially disengaged from thefemale buckle member, the second side of the securing loop becomesclamped between the first strap segment and the male buckle member.

In another aspect, the present disclosure is directed to a method forpreventing disengagement of a buckle assembly when a locking structureof the buckle assembly is accidentally released. The buckle assembly hasa disengagement prevention device configured for engagement withinsertion and receiving members of the buckle assembly to maintain theinsertion and receiving members in a coupled state under conditionswhere the insertion and receiving members are not properly engaged orthe engagement between the insertion and receiving members isaccidentally released. In an embodiment of the present disclosure, thedisengagement prevention device comprises a securing loop attached tothe receiving member. The method according to this embodiment compriseslooping the securing loop about the insertion member, inserting theinsertion member into a void formed on the receiving member, andengaging a locking structure of the insertion member with openingsformed on the receiving member. Additionally, the method can includepulling a free end of a strap held by the insertion member through thesecuring loop.

In yet another aspect of the present disclosure, a buckle assembly witha disengagement prevention device is provided to an infant supportstructure. The infant support structure has a panel configured to bedeployed upon a support frame between at least two anchor points of thesupport frame, an insert disposed within an aperture formed on thepanel, and a plurality of buckle assemblies each for releasably securingthe panel to the at least two anchor points of the support frame. Eachof the buckle assemblies comprises first and second buckle members and adisengagement prevention device configured for engagement with the firstand second buckle members to maintain the first and second bucklemembers in a coupled state under conditions where the first and secondbuckle members are not properly engaged or the engagement between thefirst and second buckle members is accidentally released. The firstbuckle member has a first strap holding structure configured toadjustably affix the first buckle member to a first strap segment. Thesecond buckle member is configured to couple with the first bucklemember, the second buckle member having a second strap holding structureconfigured to affix the second buckle member to a second strap segment.

In an embodiment of the infant support structure, the disengagementprevention device comprises a securing loop having a first side attachedto the female buckle member and a second side configured to engage withthe male buckle member.

In another embodiment of the infant support structure, the insert has afirst planar configuration and a second non-planar configuration.Responsive to an infant being placed onto the insert, the insertundergoes an elastic deformation thereby transitioning from the firstplanar configuration into the second non-planar configuration in whichthe insert urges a spine of the infant into a convex curve.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentdisclosure will become better understood with regard to the followingdescription, appended claims and accompanying drawings.

FIG. 1 shows buckle members used in a buckle assembly with adisengagement prevention device used in accordance with an embodiment ofthe present disclosure.

FIG. 2 shows a buckle assembly with a disengagement prevention device inaccordance with an embodiment of the present disclosure.

FIG. 3A shows the buckle assembly of FIG. 2 in a disengaged state inaccordance with an embodiment of the present disclosure.

FIG. 3B shows the buckle assembly of FIG. 2 in a partially disengagedstate where the disengagement prevention device prevents fulldisengagement of the buckle assembly in accordance with an embodiment ofthe present disclosure.

FIG. 4 shows a buckle assembly with a disengagement prevention device inaccordance with another embodiment of the present disclosure.

FIG. 5 shows a buckle assembly with a disengagement prevention device inaccordance with another embodiment of the present disclosure.

FIG. 6 shows a flow diagram illustrating a method for engaging thebuckle assembly with a disengagement prevention device, in accordancewith an embodiment of the present disclosure.

FIG. 7A shows an application of the buckle assembly with a disengagementprevention device in accordance with embodiments of the presentdisclosure.

FIG. 7B shows an enlarged view of region A shown in FIG. 7A.

DETAILED DESCRIPTION

Buckle assemblies, such as those of the side release buckle type,provide a secure coupling for harnesses and closures. However, siderelease buckles can be susceptible to disengagement if not properlyengaged or accidentally released. Embodiments of the present disclosureprovide buckle assemblies and related methods and techniques formaintaining buckle members in a coupled state even under conditionswhere the buckle members are not properly engaged or the engagementbetween the buckle members is accidentally released.

Embodiments of the buckle assembly according to the present disclosureinclude a first buckle member with a first strap holding structureconfigured to adjustably affix the first buckle member to a first strapsegment, and a second buckle member configured to couplingly engage withthe first buckle member, where the second buckle member has a secondstrap holding structure configured to affix the second buckle member toa second strap segment. A disengagement prevention device is configuredfor engagement with the first and second buckle members to maintain thefirst and second buckle members in a coupled state under conditionswhere the first and second buckle members are not properly engaged orthe engagement between the first and second buckle members isaccidentally released.

Embodiments of the present disclosure are described herein withreference to FIGS. 1-7B. Throughout the disclosure, like elements arereferenced by common reference numerals.

FIGS. 1-3B illustrate an embodiment of a buckle assembly with adisengagement prevention device (hereinafter “buckle assembly”)according to the present disclosure which is designated generally bynumeral 50 in FIG. 2 and FIG. 3A.

FIG. 1 shows an embodiment of buckle members 51, 52 used in buckleassembly 50. Buckle members 51, 52 are male and female buckle members,respectively, commonly used in buckle assemblies of the side releasebuckle type which is configured to be unlocked from two opposite lateralsides. Male buckle member 51 (also referred to as an insertion member)includes two axially extended locking bars 53 a, 53 b, collectivelyforming a locking structure, and a center bar 54 spaced between thelocking bars 53 a, 53 b. Female buckle member 52 (also referred to as areceiving member) has a void 55 formed thereon for receiving lockingbars 53 a, 53 b and center bar 54 of male buckle member 51. Two sidenotches 56 a, 56 b, which are respectively formed as openings in the twoopposite lateral sidewalls and extend into void 55, retain locking bars53 a, 53 b of male buckle member 51.

Male buckle member 51 includes a first strap holding structure formed bya first through hole 61 and a second through hole 60 separated from eachother by a cross member 63. Adjacent to a rear surface 65, female bucklemember 52 has a through hole 64 forming a second strap holdingstructure.

When male buckle member 51 is inserted into void 55 of female bucklemember 52, as shown in FIG. 3, locking bars 53 a, 53 b are forced bytheir resilient material property into engagement with the notches 56 a,56 b to lock male buckle member 51 to female buckle member 52. Squeezinglocking bars 53 a, 53 b inwards releases locking bars 53 a, 53 b fromside notches 56 a, 56 b, disengaging male buckle member 51 from femalebuckle member 52.

Referring to FIG. 3, a first strap portion 70 is attached to male bucklemember 51 by threading an end of the first strap portion 70 throughfirst through hole 61, over cross member 63 and through second throughhole 60. A second strap portion 71 is attached to female buckle member52 by threading a free end of the second strap portion 71 through thesecond strap holding structure (e.g., the through hole 64). The free endof second strap portion 71 is further looped over rear surface 65 offemale buckle member 52 and joined to another region of second strapportion 71.

In one embodiment, the free end and the other region of second strapportion 71 can be joined by stitching, such as a box stitch, forexample. In other embodiments, the free end and the other region of thesecond strap portion 71 can be joined by welding, for example, in caseswhere second strap portion 71 is constructed of a plastic material, suchas nylon. In still other embodiments, the free end and the other regionof second strap portion 71 can be joined using rivets or clamps. Othermeans for joining the free end and the other region of second strapportion 71 are suitable without departing from the spirit and scope ofthe present disclosure.

Buckle assembly 50 includes a disengagement prevention device configuredfor engagement with male and female buckle members 51, 52 to maintainthe buckle members 51, 52 in a coupled state under conditions wherebuckle members 51, 52 are not properly engaged or the engagement betweenbuckle members 51, 52 is accidentally released. In the presentembodiment, the disengagement prevention device comprises a securingloop 72 attached to female buckle member 52 by way of the stitching, orother bonding method, used to join the free end and the other region ofsecond strap portion 71. Securing loop 72, when engaged, as shown inFIG. 3A and described in greater detail below with reference to the flowdiagram of FIG. 6, prevents male buckle member 51 from fully separatingfrom female buckle member 52 in the case of a failure of the lockingstructure (e.g., locking bars 53 a, 53 b) properly engaging with sidenotches 56 a, 56 b of female buckle member 52. Failure can be a resultof locking bars 53 a, 53 b not fully engaging with side notches 56 a, 56b, inadvertent release of locking bars 53 a, 53 b from side notches 56a, 56 b, and breakage of one or both of locking bars 53 a, 53 b, forexample.

FIG. 3A shows securing loop 72 in an engaged configuration. As shown, afirst side of securing loop 72 is secured to female buckle member 52. Asecond side of securing loop 72 is secured around male buckle member 51between male buckle member 51 and an extending portion 73 of first strapportion 70. In this configuration, if male buckle member 51 and femalebuckle member 52 become decoupled from one another, as shown in FIG. 3B,securing loop 72 securely maintains male buckle member 51 and femalebuckle member 52 in close proximity to each other, thus preventingcomplete release of buckle assembly 50.

When male buckle member 51 is decoupled from female buckle member 52 asshown in FIG. 3B, securing loop 72 becomes clamped between a surface ofmale buckle member 51 and extended portion 73 of first strap portion 70.Extended portion 73 is the part of the first strap that is affixed, atits end, to some object, such as a flap of a backpack or a segment of aharness. Since extended portion 73 is unable to release from the objectit is attached to, extended portion 73 becomes pulled taut by securingloop 72. Thus, extended portion 73 is drawn towards male buckle member51, resulting in securing loop 72 becoming trapped therebetween.

Securing loop 72 can be fabricated from nylon paracord, for example. Inother embodiments, securing loop 72 can be fabricated from rubber orother elastic material. In embodiments where securing loop 72 is anelastic material, the material can be selected based on an appropriateelasticity for the intended application. Thus, a material having a lowerelasticity, or requiring greater force to stretch the material, can beselected for applications where separation of male buckle member 51 andfemale buckle member 52 during a failure is to be kept to a minimum,such as in safety harnesses and the like, for example. Other flexible,elastic or nonelastic materials having appropriate load bearing strengthare also suitable for securing loop 72. For example, nylon paracord canhave a strength of up to 600 pounds test. In some embodiments, nylonparacord having a load bearing strength of 200 pounds test can be used.The particular load bearing strength of securing loop 72 can be dictatedby the intended application needs, and thus is not limited to thestrengths provided herein.

It can be appreciated by one of ordinary skill in the art, in light ofthe description herein of the various exemplary embodiments, that thepresent disclosure is not limited to having securing loop 72 attached tofemale buckle member 52. Rather, in some embodiments, securing loop 72can be attached to male buckle member 51, while female buckle member 52is configured to provide an adjustable strap length.

FIG. 4 and FIG. 5 show other configurations for attaching securing loop72 to the side release buckle assembly 50 according to other embodimentsof the present disclosure.

In FIG. 4, the first end of securing loop 72 is attached to femalebuckle member 52 by way of the loop formed by the joining of the freeend of second strap portion 71 and the other region of second strapportion 71. In this configuration, securing loop 72 is not held by thestitching used to join the free end of second strap portion 71 and theother region of second strap portion 71, thus avoiding situations wherethe stitching may weaken the integrity of securing loop 72 caused byperforation of securing loop 72 by the thread.

FIG. 5 shows another configuration for attaching securing loop 72 tobuckle assembly 50. In the embodiment shown in FIG. 5, securing loop 72can be provided as a separated device, rather than integrated withbuckle assembly 50. In the present embodiment, securing loop 72 can beprovided as an after-market device. As shown in FIG. 5, securing loop 72can be attached to female buckle member 52 by passing female bucklemember 52 through securing loop 72 such that second strap portion 71 isin contact with a side of securing loop 72. The free side of securingloop 72 is then looped through through-hole 64 (second strap holdingstructure). The free side of securing loop 72 can then be engaged withmale buckle member 51 as described above with respect to FIG. 3A.

In other embodiments, the free side of securing loop 72 can be loopedaround male buckle member 51 in a similar manner as used with femalebuckle member 52 shown in FIG. 5. In the present embodiment, securingloop 72 can be disengaged from either female buckle member 52 or malebuckle member 51 without deviating from the present disclosure.

FIG. 6 presents a flow diagram showing a process for engaging thesecuring loop in accordance with some embodiments of the presentdisclosure. At block 601, securing loop 72, attached to a receivingmember (female buckle member 52), is looped about an insertion member(male buckle member 51). Insertion member 51 is inserted into a voidformed on receiving member 52 at block 603. At block 605, the lockingstructure (locking bars 53 a, 53 b) of insertion member 51 engages withopenings (side notches 56 a, 56 b) formed on receiving member 52. Onceinsertion member 51 is coupled to receiving member 52, a free end of astrap 70 held by insertion member 51 is pulled through securing loop 72at block 607. Releasing securing loop 72 from insertion member 51 isaccomplished by performing the process shown in FIG. 6 in reverse,starting with block 607 and ending with block 601.

FIG. 7A-7B show an example of an embodiment of the present disclosureemployed in a practical application, namely an infant support structureas disclosed in the inventor's U.S. Pat. No. 9,943,175, which isincorporated herein by this reference in its entirety.

FIG. 7A depicts an infant support device 10. Infant support device 10has a support frame 12 comprising a plurality of interconnected supportframe members 14. Support frame 12 is configured to support a loadexerted onto it by a weight of an infant with a predetermined factor ofsafety. Support frame 12 can be made of any material having sufficientstrength to withstand such loads. The materials may include plastics,wood, an array of metals and their alloys, and combinations thereof.

In an embodiment, support frame members 14 are configured tointerconnect with one another to form support frame 12 either by matingdirectly with one another or via couplings 16. Infant support device 10further includes a fabric panel 18 disposed between four anchor points19 on support frame 12. Fabric panel 18 has an aperture 20 within whichmesh insert 22 is disposed.

Fabric panel 18 is attached to each of anchor points 19 (four in thisembodiment) by way of a buckle assembly 50 affixed to each of fourcorners of fabric panel 18. Buckle assembly 50 corresponds to buckleassembly 50 described above with reference to the embodiment of FIGS.1-3B and as shown in enlarged region A shown in FIG. 7B. Buckle assembly50 is equipped with securing loop 72 in the manner described above withreference to FIGS. 1-3B. With the securing loop 72 engaged, buckleassembly 50 is prevented from fully releasing unintentionally, asdescribed above for buckle assembly 50 in the embodiment of FIGS. 1-3B,thus reducing the risk of the infant support device 10 decoupling fromthe support frame 12 while an infant is being held thereby. It isunderstood that buckle assemblies 50 described above with reference tothe embodiments of FIGS. 4 and 5 can also be alternatively used in theinfant support device 10 without departing from the spirit and scope ofthe present disclosure.

The above-described aspects and embodiments of the present disclosureare intended to be illustrative rather than restrictive, and are notintended to represent every embodiment of the present disclosure.Various modifications and variations can be made without departing fromthe spirit or scope of the disclosure as set forth in the followingclaims both literally and in equivalents recognized in law.

What is claimed is:
 1. A buckle assembly comprising: a first buckle member having a first strap holding structure configured to adjustably affix the first buckle member to a first strap segment; a second buckle member configured to couple with the first buckle member, the second buckle member having a second strap holding structure configured to affix the second buckle member to a second strap segment; and a disengagement prevention device configured for engagement with the first and second buckle members to maintain the first and second buckle members in a coupled state under conditions where the first and second buckle members are not properly engaged or the engagement between the first and second buckle members is accidentally released.
 2. A buckle assembly as in claim 1, wherein the disengagement prevention device comprises a securing loop having a first side attached to the second buckle member and a second side configured to engage with the first buckle member.
 3. The buckle assembly as in claim 2, wherein the securing loop is constructed of a flexible material.
 4. The buckle assembly as in claim 2, wherein the first side of the securing loop is sewn between portions the second strap segment.
 5. The buckle assembly as in claim 2, wherein when the first buckle member becomes disengaged from the second buckle member, the second side of the securing loop becomes clamped between the first strap segment and the first buckle member.
 6. The buckle assembly as in claim 2, wherein the first side of the securing loop is secured to the second buckle member by looping the securing loop through the second strap holding structure and around the second buckle member.
 7. The buckle assembly as in claim 2, wherein the first side of the securing loop is held in proximity to the second buckle member by a loop of the second strap segment.
 8. The buckle assembly as in claim 7, wherein the loop of the second strap segment is formed by a free end of the second strap segment passed through the second strap holding structure and joined to a remaining portion of the second strap segment.
 9. The buckle assembly as in claim 8, wherein the free end of the second strap segment is joined to a remaining portion of the second strap segment using a box stitch.
 10. The buckle assembly as in claim 8, wherein the free end of the second strap segment is joined to a remaining portion of the second strap segment by heat welding.
 11. The buckle assembly as in claim 8, wherein the free end of the second strap segment is joined to a remaining portion of the second strap segment using a rivet.
 12. A buckle assembly, comprising: a male buckle member including: an insertion portion having a pair of opposing locking structures disposed at a distal end of the insertion portion, and a first strap holding structure formed at a proximal end of the insertion portion, the first strap holding structure being configured to affix the male buckle member to a first strap segment; a female buckle member including: a receiving void configured to receive the insertion portion of the male buckle member, the receiving void having openings extending perpendicular to a long axis of the female buckle member, the openings being configured to holdingly receive the respective locking structures, and a second strap holding structure formed opposite to the receiving void, the second strap holding structure being configured to affix the female buckle member to a second strap segment; and a disengagement prevention device configured for engagement with the male and female buckle members to maintain the male and female buckle members in a coupled state under conditions where the male and female buckle members are not properly engaged or the engagement between the male and female buckle members is accidentally released.
 13. A buckle assembly as in claim 12, wherein the disengagement prevention device comprises a securing loop having a first side attached to the female buckle member and a second side configured to engage with the male buckle member.
 14. The buckle assembly as in claim 13, wherein the securing loop is constructed of a flexible material.
 15. The buckle assembly as in claim 14, wherein the flexible material is nylon paracord.
 16. The buckle assembly as in claim 13, wherein the first side of the securing loop is sewn between portions the second strap segment.
 17. The buckle assembly as in claim 13, wherein the first side of the securing loop is held in proximity to the female buckle member by a loop of the second strap segment formed by a free end of the second strap segment passed through the second strap holding structure and joined to a remaining portion of the second strap segment.
 18. The buckle assembly as in claim 17, wherein the free end of the second strap segment is joined to a remaining portion of the second strap segment using a box stitch.
 19. A method for preventing disengagement of a buckle assembly when a locking structure of the buckle assembly is accidentally released, the method comprising: looping a securing loop, attached to a receiving member, about an insertion member; inserting the insertion member into a void formed on the receiving member; and engaging a locking structure of the insertion member with openings formed on the receiving member.
 20. An infant support structure comprising: a panel configured to be deployed upon a support frame between at least two anchor points of the support frame; an insert disposed within an aperture formed on the panel; and at least two buckle assemblies according to claim 1 each for releasably securing the panel to the respective at least two anchor points of the support frame. 